JIT生产系统中在制品库存对工人行为的激励研究

上海交通大学硕士学位论文JIT生产系统中在制品库存对工人行为的激励研究姓名：王文文申请学位级别：硕士专业：企业管理指导教师：任建标200601011JITJITJIT603201010218ABSTRACT3ASTUDYONTHEMOTIVATIONALEFFECTOFWIPONWORKER’SBEHAVIORSINJITSYSTEMSABSTRACTItisknownthatthelowWIPwouldresultinthelowproductivity.Infact,thelowWIPisassociatedwithhighproductivityinJITsystems.Itistruethattheimprovementofmanagementplaysanimportantroleinit.However,thestudyisintenttoanalyzethemotivationaleffectoflowWIPonworker’sbehaviorsandwilldrawtheconclusionthattheprocessingtimeofworkersisaffectedbythelowWIPintheproductline.ThedissertationtendstoexplorethemotivationaleffectofWIPonworker’sbehaviorsthroughmockproductlineexperimentandanalyzedtheIndependenceAssumptionwidelyusedinproductlinemodules;togetherwithsomeoverviewsofformerstudies,theassumptionfortheexperimentwasformedandalsothemockexperiment.60highschoolstudentsparticipatedintheexperimentanddividedinto20groupsrandomlywith3studentseachgroup.Amongthe20groups,10randomlychosengroupsweredelegatedtodotheexperimentwithhighWIP,theotherswithlowWIP.ExceptforthedifferentABSTRACT4treatmentinWIP,thetwotypesofexperimentareallthesame.Thestudentswereaskedtofinishestoysofpianoaccordingtorules.ThedatawasprocessedwithAssumptionTesttoexplorethedifferenceofworker’sbehaviorsindifferenttreatment.Theexperimentresultsare:theactualproductivityoflowWIPlineswas18%higherthanthepredictedoneandtheactualidletimeoflowWIPlineswaslowerthanthepredictedone;theaverageBetween-worker,Within-teamprocessingtimewasaffectedbytheircoworkersandtherewerenosucheffectinhighWIPlines;theworkerswouldincreasetheirprocessingtimewhencausingblockingorstarvingofproductslines.KEYWORDS:WIP,motivationaleffect,worker’sbehaviors,JIT2006116200611620061161JIT1.1JIT1.1.1JIT21JIT(Justintime):1.2.3.4.5.JITJITJITJITJIT2JITJITJIT1.1.2JIT?JIT31.21.2.11.2.2440[1]JIT5JITJIT[2][3][4]JITJIT6JITJITJITJIT2.1JIT2-12-17//2-12-1Figure2-1TheOperationsManagementandHumanResourceManagementInterface/////////82.1.1[5]20019Herbie[6]2.1.2[5]10HerbieHerbieHerbie11-2.1.3[3]122.2JIT2.2.1[5][9][10][5]131)2)3)4)5)/6)7)1985YokogawaElectricHewlettPackardYHPHPHP[5]YHPWIP2YHP1471056147346[11]15[18]-161)Doerr[13]Schultz[14]172)Schultz[3][15][12]Schultz[14]17[3][16]18[17][18]//1980/197019CONWIP[19]CONWIP[19][20]/([21])201)a)b)c)2a)b)/c)3a)b)c)4a)b)c)212.2.2[7]//22/23[9]HenryFordHighlandPark900[22][23]24Boswell[24]2512[25]263-t5015-27JIT3.1JITJIT3.1.1JIT40Shanthikumar[26]Conway[11][1]28Schultz[8]191790.7Schultz[8]Schonberger[27]JIT3.1.2JITJIT[28]JIT29JITParkerSlaughter[29]SewellWilkinson[30]JITJITDelridg[31]JITGroebnerMerz[32]JITJITKlein[33]JIT30BrownMitchell[34]18JITJITJITJITBrownMitchellDoerr[13]Doerr[13]JIT20002001313.2JITHAHB32H1AH1BH2AH2BAB2A2BH3H433H5H634JIT4.14.1.160151716.7322860320102024.1.24-14-24-54-2W1W2W3W14-34-3W311W24-4W14-4W211W34-5W1W24-535W3104-1Figure4-1PartstoFix4-2Figure4-2TheSketchmapofexperimentW1W2W3364-3W1Figure4-3TheMaterialsandFinishedProductsofW14-4W2Figure4-4TheMaterialsandFinishedProductsofW24-5W237Figure4-5TheMaterialsandFinishedProductsofW31423W1W2W2W31064.1.320661010123831)2)3)666104.2t4.2.1H34-14-1H339184-1Table4-1PredictedandActualProductivityofaLow-InventoryLinen15.314.01020.815.010tt=2.24,p=0.02WSWF(WS–WF)/WS()()SFSMS−+−(1)4-2(1)H44-2Table4-2PredictedandActualIdleTimeofaLow-InventoryLinen16.79.961010.67.3310tt=1.98,p=0.03404-3Table4-3ActualProductivityofHigh-andLow-InventoryLinesn21.317.61020.815.010tt=0.09,p=0.9310.6%4-31.4%4.2.2H54-44-44-4114-4H5414-4Table4-4AverageBetween-Worker,Within-TeamStandardDeviation46.529131.81260.01n=10tH64-5W1W2126640.5114-5(p)Table5CorrelationandSignificance(pvalue)ofAverageProcessingTimeW1W20.1850.710()(0.30)(0.01)W1W30.2750.921()(0.21)(0.00)W2W3-0.3730.589()(0.13)(0.03)n=10p42H64.2.3HAH1AH2A4-64-6Table6DifferencesinProcessingTimeswhenCausingIdleTimesnH2A21%0.03*20H1A3%0.0120*H2AtH1A4-6H1A4.2.4HBHAt4-74-7H1BH2B434-7Table4-7DifferencesinProcessingTimeswhenclosetoBeingIdlenH2B4%20H1B(4%)20()H2Bt4.3Doerr,Mitchell,KlastorinBrownDoerr[13]H3Doerr[13]4-83Doerr[13]Doerr[13]44HAHBDoerr[13]4-8Doerr(1996)[13]Table4-8CycleTimeDatafromDoerretal.(1996)5.15.04.94.35.15.35.45.17.46.96.86.47.16.98.47.28.87.910.98.87.16.79.18.07.16.67.56.56.46.37.66.81.91.53.12.31.20.92.01.54.4DoerrHA1)452)3)465.1-JIT5.2JIT475.348[8]495.460/1.2.3.18[8]5051[1]Shanthikumar,J.G.,D.D.Yao,QueueingNetworksWithBlocking.North-Holland,Amsterdam,H.G.Perros,T.Altiok,eds.,325-345[2]Lock,E.A.,G.P.Latham,GoalSetting:AMotivationalTechniquethatWorks!,EnglewoodCliffs,NJ,Prentice-Hall,1984,283-296[3]Lawler,E.E.,Employeeinvolvementmakesadifference,J.QualityParticipation,1999,22(5),18-20[4]Guzzo,R.A.,E.Salas,TeamEffectivenessandDecisionMakinginOrganizations,SanFrancisco,CA,Jossey-Bass,1995,26-32[5]BoudreauJohn,McClainJohn,etc,OntheInterfaceBetweenOperationsandHumanResourcesManagement,Manufacturing&ServiceOperationsManagement,2003,1523-4614,179-202[6]Goldratt,E.M.,J.Cox,TheGoal:AProcessofOngoingImprovement,Croton-on-Hudson,NY,NorthRiverPress,1984,142-151[7]Vroom,V.,WorkandMotivation,NewYork,Wiley,1964,68-73[8]Schultz,K.L.,D.C.Juran,J.